Weil-McLain CGi Gas Boiler Series 4 User manual

Brand: Weil-McLain

Model: CGi Gas Boiler Series 4

Category: Water heaters & boilers

Type: User manual

Part Number 550-142-301/0420

Do not store or use gasoline or other ﬂammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your

building.

• Immediately call your gas supplier from a neighbor’s phone. Follow

the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁre department.

Installation and service must be performed by a qualiﬁed installer, service

technician or the gas supplier.

If the information in this manual is not followed exactly, a ﬁre or

explosion may result, causing property damage, personal injury or

loss of life.

CGa Series 3, CGi Series 4,

EG Series 5, PEG Series 5,

LGB Series 2

Gas-Fired Boilers

User’s

Information

Manual

INSTALLER:

Please take time to review this User’s information

Manual with the boiler owner. Explain all maintenance

and service

procedures and the correct Operating

Instructions.

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

Please read this page ﬁrst

How to use this

manual . . .

The Boiler manual is for use only by a qualiﬁed heating installer/service technician.

Refer only to this User’s Information Manual for your reference. Improper installation,

adjustment, alteration, service or maintenance can cause property damage, personal

injury (exposure to hazardous materials) or loss of life. Installation and service must be

performed by a qualiﬁed installer, service agency or the gas supplier (who must read and

follow the supplied instructions before installing, servicing, or removing this boiler. This

boiler contains materials that have been identiﬁed as carcinogenic, or possibly carcino-

genic, to humans).

Boiler service

and

maintenance

The following deﬁned terms are used throughout this manual to bring attention to the presence of hazards

of various risk levels or to important information concerning the life of the product.

Hazard

deﬁnitions

Indicates presence of hazards that will cause severe personal injury, death or substantial

property damage.

Indicates presence of hazards that can cause severe personal injury, death or substantial

property damage.

Indicates presence of hazards that will or can cause minor personal injury or property

damage.

Indicates special instructions on installation, operation or maintenance that are important

but not related to personal injury or property damage.

To . . . Read/Use . . . Pages . .

Learn

precautions

Warnings and denitions

1, 2 and 3

Prevent air

contamination

Read list of air contaminants you must avoid. If found,

either remove products permanently or isolate boil-

er and provide outside combustion air.

Identify boiler

components

The illustration on page 4 or 5, will show you the location

of the main components.

4-5

Maintain

boiler

Set up a plan for maintaining the boiler using the

schedule included in this manual. Schedule an an-

nual start-up by a qualied service technician before every

heating season.

6-12

Start –or–

Shutdown

boiler

Use the Operating Instruction sheet for the gas

valve installed on your boiler. Ask your service techni-

cian if you are unsure which one.

12-18

Troubleshoot

common

problems

Use the common problems/solutions table to resolve

typical heating system/boiler problems.

When calling or writing about the boiler— Please have the boiler model number from

the boiler rating label and the CP number from the label located on the top of the boiler

next to the air inlet connection.

Freeze protection ﬂuids —

• NEVER use automotive or standard glycol antifreeze. Use only freeze-protection ﬂuids made for hydronic systems. Follow all

guidelines given by the antifreeze manufacturer. Thoroughly clean and ﬂush any replacement boiler system that has used glycol

before installing the new boiler.

Frozen Water Damage Hazard

Residences or buildings that are unattended in severely cold weather, boiler system components failures, power outages, or other

electrical system failures could result in frozen plumbing and water damage in a matter of hours. For your protection, take preventa-

tive actions such as having a security system installed that operates during power outages, senses low temperature, and initiates an

effective action. Consult with your boiler contractor or a home security agency.

Part Number 550-142-301/0420

User’s Information Manual

Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial

property damage.

STOP!! — Read before proceeding

Products to avoid

Spray cans containing chloro/

ﬂuorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool

chemicals

Calcium chloride used for thawing

Sodium chloride used for water

softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in

clothes dryers

Chlorine-type bleaches, detergents,

and cleaning solvents found in

household laundry rooms

Adhesives used to fasten building

products and other similar products

Excessive dust and dirt

Areas likely to have

contaminants

Dry cleaning/laundry areas and

establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture reﬁnishing areas and

establishments

New building construction

Remodeling areas

Garages with workshops

Buildings under construction

(where air is contaminated with

particulates)

Air contamination

•Topreventpotentialofseverepersonalinjuryordeath,checkforproductsor

areas listed in table at right before installing boiler. If any of these contaminants

are found:

  •removecontaminantspermanently.

— OR —

  •isolateboilerandprovideoutsidecombustionair.Seenational,provincialor

local codes for further information.

Service and maintenance

•Toavoidelectricshock,disconnect electrical supply before performing

maintenance.

  •Toavoidsevereburns,allow boiler to cool before performing maintenance.

  •Youmustmaintain the boiler as outlined in the manual and have the boiler

started up and serviced at least annually by a qualiﬁed service technician

to ensure boiler/system reliability.

Boiler operation

  •Do not block ﬂow of combustion or ventilation air to boiler. This boiler is

equipped with a control which will automatically shut down the boiler

should air or vent be blocked. If vent or air blockage is easily accessible and

removable, remove it. The boiler should attempt to restart within an hour.

If blockage is not obvious or cannot be removed, have the boiler and system

checked by a qualiﬁed service technician.

  •Shouldoverheating occur or gas supply fail to shut off, do not turn off or

disconnect electrical supply to pump. Instead, shut off the gas supply at a

location external to the appliance.

  •Have the building monitored when it is vacant for an extended period.

 Safetycontrolscanshutdowntheboileratanytime.Thelossofheatcan

result in signiﬁcant damage due to freezing.

Boiler water

•DO NOT use petroleum-based cleaning or sealing compounds in boiler

system. Water seal deterioration will occur, causing leakage between sections and

damage to heating system components. This can result in substantial property

damage.

  •DONOTuse“homemadecures”or“boilerpatentmedicines”.Seriousdamage

to boiler, personnel and/or property may result.

  •Continualfreshmakeupwaterwillreduceboilerlife.Mineralbuildupinsections

reduces heat transfer, overheats cast iron, and causes section failure. Addition of

oxygen and other gases can cause internal corrosion. Leaks in boiler or piping

must be repaired at once to prevent makeup water.

  •Donotaddcoldwatertohotboiler.Thermalshockcancausesectionstocrack.

If any part of a boiler, burner or its controls has been sprayed with

or submerged under water, either partially or fully, DO NOT attempt

to operate the boiler until the boiler has been either replaced or

completely repaired, inspected, and you are sure that the boiler and

all components are in good condition and fully reliable.Otherwise,by

operating this boiler, you will cause a ﬁre or explosion hazard, and an electrical

shock hazard, leading to serious injury, death, or substantial property damage.

Saltwater Damage — The exposure of boiler components to saltwater can have both im-

mediate and long-term effects. While the immediate effects of saltwater damage are similar to

those of freshwater (shorting out of electrical components, washing out of critical lubricants,

etc.), the salt and other contaminants left behind can lead to longer term issues after the water

is gone due to the conductive and corrosive nature of the salt residue. Therefore, Weil-McLain

equipment contaminated with saltwater or polluted water will no longer be covered under war-

ranty and should be replaced.

Electrical Damage — If any electrical component or wiring came into contact with water, or

was suspected to have come into contact with water, replace the boiler with a new Weil-McLain boiler.

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

1 Gas valve

2 Pilot burner (Not shown)

3 Main burner

4 Gas manifold/orices

5 Control module

7 Vent damper (CGa only)

8 Water temperature/LWCO sensor

9 Transformer

10 Spill switch (CGa only)

12 Rollout thermal fuse element

13 Draft hood (CGa only)

14 Circulator

15 Relief valve

16 Gauge (pressure/temperature)

17 Drain valve

Boiler components

CGa Series 3

Part Number 550-142-301/0420

User’s Information Manual

1 Gas valve

2 Pilot burner (Not shown)

3 Main burner

4 Gas manifold/orices

5 Control module

6 Inducer (CGi only)

8 Water temperature/LWCO sensor

9 Transformer

11 Air pressure switch (CGi only)

12 Rollout thermal fuse element

14 Circulator

15 Relief valve

16 Gauge (pressure/temperature)

17 Drain valve

Boiler components

CGi Series 4

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

1 Gas valve

2 Pilot burner

3 Main burner

4 Gas manifold/orices

5 Control module

7 Vent damper

9 Transformer

10 Spill switch

12 Rollout thermal fuse element

13 Low water cutoff (steam boilers)

14 Limit control(s)

15 Draft hood

16 Circulator

18 Gauge (pressure or pressure/temperature)

19 Gauge glass (steam only)

20 Water temperature/LWCO sensor

(For EG/PEG water boilers - not shown)

Boiler components

EG/PEG

LGB

1 Gas valve

2 Pilot burner

3 Main burner

4 Gas manifold/orices

5 Control module

7 Vent damper

9 Transformer

10 Spill switch

12 Rollout thermal fuse element

13 Low water cutoff (steam boilers)

14 Limit control(s)

15 Draft hood

16 Circulator

18 Gauge (pressure or pressure/temperature)

19 Gauge glass (steam only)

Part Number 550-142-301/0420

User’s Information Manual

Service technician

(covered in Boiler Manual – for use only by

a qualiﬁed service technician)

Owner maintenance

(see following pages for instructions)

AnnuAl stArt-up

Inspect:

•Reported problems

•Boiler area

•Air openings

•Flue gas vent system

•Pilot and main burner ﬂames

•Water piping

•Boiler heating surfaces

•Burners, base and inlet air box

•Condensate drain system

Service:

•Oiled-bearing circulators

•Temperature/LWCO sensor

Start-up:

•Perform start-up per manual

Check/test:

•Gas piping

•Cold ﬁll and operating pressures

•Air vents and air elimination

•Limit controls and cutoffs

•Expansion tank

•Boiler relief valve

Review:

•Review with owner

Daily

•Check boiler area

•Check air openings

•Check boiler pressure/

temperature gauge

Monthly

•Check boiler interior piping

•Check venting system

•Check air vents

•Check boiler relief valve

•Check automatic air vents

(if used)

Periodically

•Test low water cutoff

Every 6 months

•Operate relief valve

End of season

•Shut down procedure

Tankless water heater (EG and PEG only)

If boiler is used to supply domestic hot water, limit

control should be set to supply adequate hot water.

Weil-McLain tankless heaters are rated at 200 °F boiler

water temperature. To get rated output, set low limit at

200 °F. Limit can be adjusted to meet system hot water

requirements.Differentialcanbesetto15°andadjusted

to control level. Lowering the differential will cause a

slight variation in water temperature but will decrease

burner on-off cycling. High limit should be set at least

20 ° above low limit.

Maintain boiler using schedule below

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

User maintenance procedures

Donotattempttoplaceboilerinoperationifspillswitch

cuts off gas ﬂow. Immediately call a service technician.

Failure to do so can cause severe personal injury, death

or substantial property damage.

Rollout thermal fuse element

CGa, CGi, EG, & PEG only

Cutsoff gas flowshouldflamerollout occur.See

Figure 1.

 Donotattempttoplaceboilerinoperationifrollout

thermal fuse element cuts off gas ﬂow. Immediately call

a service technician. Failure to do so can cause severe

personal injury, death or substantial property damage.

Spill switch

CGa, EG, & PEG only

Cuts off gas ﬂow should vent system become blocked.

SeeFigure 2.

Figure 1

Rollout thermal fuse element

Figure 2

Spill switch

Component information

Boiler area

To prevent potential of severe personal injury, death

or substantial property damage, eliminate all materials

discussed below from the boiler vicinity. If found:

• Removeproductsimmediatelyfromthearea. If

they have been there for an extended period, call a

qualiﬁed service technician to inspect the boiler and

vent system for possible damage from acid corrosion.

• Ifproductscannot be removed,immediatelycall

a qualiﬁed service technician to install an outside

combustion air source for the boiler (if not already

installed).

1. Combustible/flammablematerials—Donot

store combustible materials, gasoline or any

other ﬂammable vapors or liquids near the boiler.

Remove immediately if found.

2. Aircontaminants—Seelistingofcontaminantson

page 3.

❏ Check daily . . . . . . . . . . . . . . . . .

The boiler should be inspected and started annually, at

the beginning of the heating season, only by a qualiﬁed

service technician. In addition, the maintenance and

care of the boiler designated on page 6 and explained

on the following pages must be performed to assure

maximum boiler efﬁciency and reliability. Failure to

service and maintain the boiler and system could result

in equipment failure, causing possible severe personal

injury, death or substantial property damage.

Boiler must be serviced & maintained

The following information provides

detailed instructions for completing

the maintenance items listed in

the maintenance schedule, page 6.

In addition to this maintenance,

the boiler must be serviced and

started up at the beginning of each

heating season by a qualiﬁed service

technician.

Part Number 550-142-301/0420

User’s Information Manual

❏ Check daily . . . . . . . . . . . . . . . . .

Air openings

1. Verifythatcombustionandventilationairopenings

to the boiler room and/or building are open and

unobstructed.

Pressure/temperature gauge

or pressure gauge (steam)

1. Waterboilers— Makesurethepressurereading

on the boiler pressure/temperature gauge does

not exceed 24 psig. Higher pressure may indicate a

problem with the expansion tank or gauge.

2. Steamboilers—Makesurethepressurereadingon

theboilerpressuregaugedoesnotexceed15psig.

Higher pressure indicates a problem with the gauge

or limit control.

3. Contact a qualiﬁed service technician if problem

persists.

Venting system

Failure to inspect the vent system as noted above and

have them repaired by a qualiﬁed service technician can

result in vent system failure, causing severe personal

injury or death.

Boiler piping

Have leaks ﬁxed at once by a qualiﬁed service technician.

Continual fresh makeup water will reduce boiler life.

Minerals can build up in sections, reducing heat transfer,

overheating cast iron, and causing section failure.

1. Visually inspect for leaks around piping, circulators,

relief valve and other ﬁttings. Immediately call a

qualiﬁed service technician to repair any leaks.

1. Visuallyinspectallpartsortheue gas venting

system for any signs of blockage, leakage or joints

or deterioration of the piping.

CGa and EG boilers:

a. With boiler ﬁring, hold a candle or match below

loweredgeofdrafthood“skirt.”Ifamedoes

not blow out, but burns undisturbed, the vent

system is working properly.

Donotusepetroleum-based cleaning or sealing

compounds

inboilersystem.Severedamagetoboiler

and system components can occur, resulting in possible

severe personal injury, death or substantial property

damage.

❏ Check monthly . . . . . . . . . . . . . . . .

If ﬂame blows out or ﬂickers severely, the vent

system must be checked for obstructions or

other causes of improper venting.

b. Verify the vent damper (CGa and EG boilers)

opens before burners ignite.

3. Notify your qualiﬁed service technician at once if

you ﬁnd any problem.

Boiler relief valve . . . . . . . . .

1. Inspect the boiler relief valve (see Figure 3) and the

relief valve discharge pipe for signs of weeping or

leakage.

2. If the relief valve often weeps:

•

water boilers — the expansion tank may not

be working properly.

•

steam boilers — limit control may be set too

high or there may be system problems.

• Immediatelycontactyourqualified service

technician to inspect the boiler and system.

Figure 3 Relief valve

User maintenance procedures (continued)

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

Automatic air vents (if used)

1. SeeFigure 4.

2. Remove the cap from any automatic

air vent in the system and check

operation by depressing valve B

slightly with the tip of a screwdriver.

3. If the air vent valve appears to be

working freely and not leaking,

replace cap A, twisting all the way

on.

4. Loosen cap A one turn to allow vent

to operate.

5. Have vent replaced if it does not

operate correctly.

Pilot burner ﬂame

Proper pilot ﬂame (see Figure 5):

1. Blueame.

2. Inner cone engulﬁng thermocouple or thermopile (standing

pilot) or pilot ﬂame sensor (spark-ignited pilot).

3. Thermocouple or thermopile, or pilot ﬂame sensor glowing

cherry red.

Improper pilot ﬂame:

1. Overred— Large ame lifting or blowingpastpilotame

sensor.

2. Underred—Smallame.Innerconenotengulngpilotame

sensor.

3. Lackofprimaryair—Yellowametip.

4. Incorrectly heated pilot ﬂame sensor.

Main burner ﬂame

Proper main burner ﬂame (see Figure 6):

1. Yellow-orangestreaksmayappear(causedbydust).

Improper main burner ﬂame:

1. Overred—Largeames.

2. Underred—Smallames.

3. Lackof primary air —Yellowtippingonames

(sooting will occur).

Figure 5 Pilot burner and ﬂame, typical

Figure 6 Main burner ﬂame, typical

❏ Check monthly . . . . . . . . . . . . . . . .

Check condensate drain

system (if used)

1. Inspectcondensatedrainttingsandtubing.Verify

that condensate can ﬂow freely to drain.

Figure 4

Automatic air vent

User maintenance procedures (continued)

Part Number 550-142-301/0420

User’s Information Manual

Figure 7 Float type low water cutoff

Figure 8 Probe type low water cutoff

Probe type— See Figure 8

1. Cleanprobetypelowwatercutoffforproperoperation.

a. Turn off power to boiler and wait 5 minutes.

b. Drainwatertobottomofgaugeglass.

c. Turn on power.

d. Setthermostattocallforheat.Redneonlamponlower

water cutoff should light.

e. Wait 5 minutes. Boiler should not ﬁre.

f. Reﬁll boiler to correct water line. Red lamp should go off.

g. Wait 5 minutes. Boiler should ﬁre.

h. Return thermostat to normal setting.

Test low water cutoff – The system is equipped with a low water cutoff. Test the low water cutoff periodically

during the heating season.

Float type — See Figure 7

1. Cleanoattypelowwatercutofftoclearoatchamberof

sediment.

a. Openblowdownvalveatbottomcontrol.

b. Drainwaterintoabucket.

. Boiler pressure and temperature must be low to

avoid the potential of severe burns from steam

or hot water.

2. Check ﬂoat type low water cutoff for proper operation.

a. Turn operating control to call for heat.

b. Before water gets hot, drain to bottom of gauge glass.

Boiler should shut off after water level lowers a few inches.

c. Reﬁll boiler to correct waterline. Boiler should come back

on.

❏ Service periodically . . . . . . . . . . . .

User maintenance procedures (continued)

Figure 9 Integtrated type low water cutoff

Integrated type— See Figure 9

1. TestLWCOusingcontrolLWCOTESTbutton.

a. Duringburnerre,pressLWCOTESTbutton.

b. Burner should shut off.

2. Clean periodically (when warning occur).

a. Turn off power to boiler wait 5 minutes.

b. Drainboilertoempty.

c. Remove sensor, wipe clean.

d. Re-installsensortospecied18ft/lbstorque.

e. Reﬁll boiler to pressure, purge air.

f. Turn on boiler power.

g. Ensure proper operation resumes.

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

Operate boiler relief valve

To avoid water damage or scalding due to

valve operation, a metal discharge line must be

connected to relief valve outlet and run to a safe

place of disposal. This discharge line must be

installed by a qualiﬁed heating installer or service

technician in accordance with the instructions

in the Boiler Manual.

The discharge line must be terminated so as to

eliminate possibility of severe burns should the

valve discharge.

1. Beforeproceeding,verifythatthereliefvalveoutlethasbeen

piped to a safe place of discharge, avoiding any possibility of

scalding from hot water.

2. Read the boiler pressure/temperature gauge to make sure the

system is pressurized.

3. Lift the relief valve top lever slightly, allowing water to relieve

through the valve and discharge piping.

4. If water ﬂows freely, release the lever and allow the valve to seat.

Watch the end of the relief valve discharge pipe to ensure that

the valve does not weep after the line has had time to drain. If

the valve weeps, lift the seat again to attempt to clean the valve

seat. If the valve continues to weep afterwards, contact your

qualiﬁed service technician to inspect the valve and system.

5. If water does not ﬂow from the valve when you lift the lever

completely, the valve or discharge line may be blocked.

Immediately shutdown the boiler, following the instructions

ontheinsidejackettopOperatingInstructions.Callyour

qualiﬁed service technician to inspect the boiler and system.

❏ Service every 6

months . . . . . . . .

Figure 10 Gauge glass

❏ Service periodically

continued . . . . . . .

Clean gauge glass

Normalwaterlineonasteamboilerishalfwayupgaugeglass.See

Figure10.Cleanwhenneeded.

1. Closelowergaugecock.

2. Openpetcock.

3. Openlowergaugecockandallowasmallamountofwaterto

ﬂush out through open pet cock.

4. Close pet cock.

5. Openlowergaugecock.

6. If gauge glass breaks, close both gauge cocks and call a quali-

ﬁed service technician to replace gauge glass. Do not replace

with thin glass tubing.

Boiler pressure must be low to eliminate po-

tential of severe burns.

Oil inducer motor (CGi boilers)

1. Use only SAE 20 motor oil. DO NOT use household universal

oils.

 UseonlySAE20 motor oiltolubricatethe

inducermotor.Donotusecommonuniversal

household oils.

2. Place a few drops of oil in each of the two oiler cups on the

inducer motor.

User maintenance procedures (continued)

Part Number 550-142-301/0420

User’s Information Manual

Operating instructions

Use Table 2belowtolocatethecorrectOperatinginstructionforthegasvalvemodelinstalledonyourboiler.

Table 2

Operating

instruction

guide

Spark-ignited pilot Models Page

Honeywell VR8204/VR8304

CGa-25 thru CGa-8

EG-30 thru EG-75

PEG-30 thru PEG-55

CGi-3 thru CGi-6 17

White-Rodgers 36E

CGa-25 thru CGa-6

EG-30 thru EG-50

PEG-30 thru PEG-50

CGi-3 thru CGi-6 17

White-Rodgers 36C

CGa-7 & CGa-8

EG-55 thru EG-75

PEG-55

CGi-3 thru CGi-6 17

Robertshaw 7200

CGa-25 thru CGa-6

EG-30 thru EG-50

PEG-30 thru PEG-50

–– LGB 18

Follow boiler shutdown procedure

❏ End-of-season shutdown . . . . . . . .

2. Do not drain systemunlessexposuretofreezing

temperatures will occur.

3. Donotdrainthesystemifitis filled withan

antifreeze solution.

4. Donotshutdownboilersusedfordomesticwater

heating. They must operate year-round.

1. Follow“TO TURN OFF GAS TO APPLIANCE”onthe

Operating instructions

on the inside of the jacket

panel.Youwillalsondtheseinstructionsonpages

13through19ofthismanual.

Use the Operating instruction for the gas valve

model installed on the boiler.

Propane boilers only—Yourpropanesuppliermixesanodorantwiththepropanetomakeitspresencedetect-

able. In some instances, the odorant can fade and the gas may no longer have an odor.

• Propanegascanaccumulateatoorlevel.Smellneartheoorforthegasodorantoranyunusualodor.

If you suspect a leak, do not attempt to light the pilot.

• Usecautionwhenattemptingtolightthepropanepilot.Thisshouldbedonebyaqualiedservice 

technician, particularly if pilot outages are common.

• Periodicallychecktheodorantlevelofyourgas.

• Inspectboilerandsystematleastyearlytomakesureallgaspipingisleak-tight.

• Consultyourpropanesupplierregardinginstallationofagasleakdetector.Therearesomeproductson

themarketintendedforthispurpose.Yoursuppliermaybeabletosuggestanappropriatedevice.

Propane gas odorant

User maintenance procedures (continued)

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

Operating instructions

• Spark-ignited pilot

• Gas valve

— Honeywell VR8204/VR8304

CGa, EG-30 to EG-75,

PEG-30 to PEG-55,

Part Number 550-142-301/0420

User’s Information Manual

Operating instructions

• Spark-ignited pilot

• Gas valve — White-Rodgers 36E

CGa-25 to CGa-6,

EG-30 to EG-50,

PEG-30 to PEG-50

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

Operating instructions

• Spark-ignited pilot

• Gas valve — White-Rodgers 36C

CGa-7, CGa-8,

EG-55 to EG-75,

PEG-55,

Part Number 550-142-301/0420

User’s Information Manual

Operating instructions

• Spark-ignited pilot

• Gas valve — Robertshaw 7200

CGa-25 to CGa-6,

EG-30 to EG-50,

PEG-30 to PEG-50

Part Number 550-142-301/0420

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

Operating instructions

• Spark-ignited pilot

CGi

• Gas valve — Honeywell VR8204/VR8304, White-Rodgers 36C and 36E

Part Number 550-142-301/0420

User’s Information Manual

Operating instructions

• Spark-ignited pilot

LGB

Part No. 550-142-301/0420

Weil-McLain

500 Blaine Street

Michigan City, IN 46360-2388

http://www.weil-mclain.com

CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers

Symptom Common Causes Possible Corrections

Rapid cycling —

boiler turns on and

off frequently

Thermostat installed where drafts

or heat affect reading

Locate thermostat on inner wall away from heat sources or cool

drafts.

Heat anticipator in thermostat

adjusted incorrectly

Adjust thermostat per manufacturer’s instructions.

Incorrect limit setting Set limit according to system needs. Maximum setting is 220°F.

Increase limit setting to decrease cycling.

Insufcient water ow through

boiler

Check all valves to and from boiler. Return to proper setting.

Conrm circulator size.

Frequent release of

water through relief

valve

Expansion tank sized too small Call qualied service technician to check expansion tank

operation and size.

Flooded expansion tank Call qualied service technician to check expansion tank

operation.

Inoperative limit control Call qualied service technician to replace limit control.

Need to frequently

add makeup water

Leaks in boiler or piping Have qualied service technician repair leaks at once to avoid

constant use of makeup water. Makeup water can cause

mineral deposits which, in turn, can cause boiler section failure.

Do not use petroleum-base stop-leak compounds.

Black water

condition

Oxygen corrosion due to leaks in

boiler and piping

Have qualied service technician repair at once. Keep pH of

water between 7.0 to 8.5.

Popping or

percolating noise

heard in boiler

Mineral deposits in sections due

to constant use of makeup water

Call qualied service technician to de-lime boiler, if necessary.

In some cases, deposits will be too heavy to remove with de-

liming procedures.

Have qualied service technician repair leaks to eliminate need

for constant makeup water.

Incorrect pH of boiler water Call qualied service technician to check pH level and correct.

pH should be maintained between 7.0 to 8.5.

Insufcient water ow through

boiler

Check all valves to and from boiler. Return to proper setting.

Conrm circulator size.

Metal akes found in

vent outlet or vent —

ueway corrosion

Contaminated combustion air

supply — See page 3 in this

manual.

Remove any contaminating products. See page 3 in this

manual.

Provide outside air for combustion.

Condensation of combustion

gases in boiler sections

Have qualied service technician inspect system piping and con-

trols to verify proper regulation of return water temperature.

Some radiators or

baseboard units do

not heat or are noisy

Air in system Bleed air from system through air vents in radiators or

baseboard units.

Low system pressure Fill to correct pressure.

Check for leaks in boiler or piping. Have qualied service

technician repair at once.

High limit set too low Adjust high limit to higher setting.

Common problems and solutions

Weil-McLain CGi Gas Boiler Series 4 User manual

Brand: Weil-McLain

Model: CGi Gas Boiler Series 4

Category: Water heaters & boilers

Type: User manual

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Weil-McLain CGi Gas Boiler Series 4 User manual

Weil-McLain CGi Gas Boiler Series 4 User manual

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